Table of Contents
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EVO: Oiling & Lubrication
Trans/Primary Oiling
Click here for primary oil change intervals and capacities in the REF section of the Sportsterpedia.
Checking Primary Oil Level
If the motorcycle has been operated recently, wait app. 10 minutes before checking the primary oil to allow the oil to settle in the case.
Park the motorcycle on a level surface and stand it upright (use an assistant, a lift etc.)
Do not check primary oil level with the bike on it's side stand.
On the 1986-1990 models, the oil level screw (stock is Philips-head) is located on the side of the primary cover, forward from the clutch cable mount and below the shifter lever. Oil should seep (not pour) from the hole, bike upright, with the oil level screw removed. If not, proper oil level is achieved by removing the clutch adjustment access cap and slowly filling the primary with oil until it pours out the oil level hole. When it's just seeping from that hole, replace the oil level screw and the inspection cap. The Oil Drain Plug is located on the lower/rear of the left-side engine case.
On the 1991-1993 models, the oil level bolt is located at the rear of left engine case, rearward of the oil drain plug. Oil should seep (not pour) from the hole with the oil level screw removed. If not, proper oil level is achieved by removing the clutch adjustment access cover and slowly filling the primary with oil until it pours out the oil level hole. When it's just seeping from there, replace the screw and the inspection cover. The Oil Drain Plug is located on the lower/rear of the engine case.
On the 1994-2003 models, the clutch inspection cover (Derby Cover) is removed. The proper level of oil, when the bike is upright, NOT ON THE SIDE STAND (you'll need a helper or a lift), is when the oil level is just at the bottom edge of the clutch diaphragm spring. The Oil Drain Plug is located on the lower/rear of the left-side engine case.
Note that for 1994-later, the manual says “Verify that lubricant level is even with bottom of clutch diaphragm spring.” Not higher or lower, but even with the diaphragm spring. It also includes this warning: “Do not overill the primary chaincase with lubricant. Overfilling may cause rough clutch engagement and incomplete disengagement (or clutch drag).”
On the 2004-2017 models, the clutch inspection cover (Derby Cover) is removed. The proper level of oil, when the bike is upright, NOT ON THE SIDE STAND (you'll need a helper or a lift), is when the oil level is just at the bottom edge of the clutch diaphragm spring. The Oil Drain Plug was moved to the lower/rear of the Primary Cover.
If the oil level is too low, you may add oil through the clutch inspection cover to raise it to the specified level.
Oil quantity needed for a typical oil change (after the bike is warmed to operating temperature and then allowed to slightly cool) is between 28oz and 32oz.
Pics
Click on a pic to enlarge:
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Primary/Transmission oil drain & oil site level bolts on a 1991-1993 Sportsters 1) | Primary/Transmission oil fill hole on a 1991 Sportster 2) |
Primary / Transmission Vent
Click here to diagnose leaks from the vent hose.
1998 transmission vent hose. 5) | ||
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2000 transmission vent hose. 6) | |
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